Development of Processing Windows for HVOF Carbide-Based Coatings

Abstract

Optimized processing windows for spraying high-quality metal carbide-based coatings are developed using particle diagnostic technology. The cermet coatings were produced via the high-velocity oxygen fuel (HVOF) spray process and are proposed for service applications such as marine hydraulics. The traditional “trial and error” method for developing coating process parameters is not technically robust, as well as being costly and time consuming. Instead, this contribution investigated the use of real-time monitoring of parameters associated with the HVOF flame jets and particles using in-flight particle diagnostics. Subsequently, coatings can be produced with knowledge concerning the molten particle size, temperature, and velocity profile. The analytical results allow identification of optimized coating process windows, which translate to coatings of lower porosity and improved mechanical performance.

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This article is an invited paper selected from presentations at the 2015 International Thermal Spray Conference, held May 11-14, 2015, in Long Beach, California, USA, and has been expanded from the original presentation.

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Acknowledgments

The authors thank messieurs Maurice Valimberti and Peter Hawkey from United Surface Technologies; Peter Richings and Craig Boschen from MacTaggart Scott Australia; and Andrew Moore from Swinburne University for expert assistance in the preparation and procurement of samples used in this work. The authors acknowledge the support of the Defence Materials Technology Centre, which was established and is supported by the Australian Government’s Defence Future Capability Technology Centre (DFCTC) initiative. This work was performed in part at the Biointerface Engineering Hub in the Victorian Node of the Australian National Fabrication Facility (ANFF).